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E7153 DIESEL FUEL PUMP REPLACEMENT INSTRUCTIONS 1998 2002 Dodge Ram With Cummins ISB Diesel Engine Thoroughly read and understand these instructions prior to replacing the fuel pump X91205 EXISTING VEHICLE FUEL PUMP AIRTEX IMPROVED FUEL PUMP SAFETY INFORMATION Repair procedures tools and parts to service motor vehicles and the experience of the person performing the work make it impossible to describe all ways or conditions under which motor vehicles are or may be serviced or to provide cautionary statements regarding hazards that may result Standard and accepted safety precautions and equipment should be used when handling toxic or flammable materials Safety goggles other protection and appropriate clothing long sleeve shirt trousers and safety shoes are required Make sure your work area is well ventilated and not exposed to heat electricity or open flames No smoking Clean up spills immediately and have a Class B or C fire extinguisher readily accessible Consult appropriate repair manuals for any required special tools SAFETY PRECAUTIONS Work on a level surface Use safety stands for supporting vehicles and other heavy components not a jack Keep an ABC fire extinguisher close by Work in a well ventilated area Do not smoke or allow open flames or sparks in and around the work area Allow the engine and vehicle to cool before beginning work on any part of the fuel system Avoid inhaling fuel fumes and prolonged contact with skin Immediately wash any part of the body that has come in contact with fuel Store fuel in approved containers only Clean up spills quickly and dispose of according to local codes Disconnect battery cables prior to beginning work on any component of the fuel system This fuel pump assembly will not correct any issues related to faulty injectors or fuel injection pumps fuel filters pressure regulators or any other malfunctioning component of the fuel system Consult manufacturer specific service and repair manuals for procedures to properly diagnose fuel system failures This fuel pump is not approved for aircraft or marine use Running this pump dry will result in damage to the pump Keep pump fuel tank lines and fittings clean Dirt and contamination entering the fuel system will damage the pumping system as well as the injectors INSTALLATION 1 Remove the negative cables from both batteries and assure that they cannot accidentally make a connection to the batteries during the fuel pump replacement procedure 2 Place a drain pan under the vehicle to catch any fuel spills 3 Thoroughly clean the area around the old fuel pump and fuel lines 4 Disconnect the fuel inlet line quick connector at the back of the pump 5 Remove the fuel inlet line support clamp from the pump mounting bracket A Instructions 4 5 B Pump C 2 Washers 1 Capnut D 3 Mounting Nuts Washers Fuel Line Quick Connector Fuel Inlet Line Support Clamp E 90 Degree Adapter Fitting 6451 X91205 Instructions 5 8 08 9 30 AM Page 1 6 Remove the fuel line banjo bolt from the pump outlet Discard the banjo bolt and both copper sealing washers 7 Disconnect the vehicle harness electrical connector from the pump and remove the cable clamp from the mounting bracket 8 Remove the 3 pump mounting nuts and washers from the old pump Then remove the pump from the engine bracket 9 Install one of the supplied copper sealing washers on the new pump Then place the pump outlet loosely into the vehicle fuel line banjo fitting 10 Align the pump assembly mounting studs to the pump mounting bracket on the vehicle Install the 3 supplied washers and nuts Torque to 9 ft lbs 108 in lbs X91205 11 Reinstall original cable clamp to mounting bracket on new pump to correctly route pump electrical connector 12 Install the 2nd supplied copper sealing washer and capnut Torque to 2 ft lbs 25 in lbs Do not overtighten CAUTION TO PREVENT LEAKS ALWAYS USE NEW SUPPLIED WASHERS AND TORQUE THE CAPNUT TO SPECIFICATIONS 13a Ensure there is adequate clearance to connect the fuel supply line without binding kinking or restricting If clearance is an issue install 90 degree adapter fitting by pressing onto fuel inlet until it snaps into place IMPORTANT ONCE INSTALLED THE 90 DEGREE ADAPTER FITTING IS NOT REMOVABLE WITHOUT USE OF SPECIAL TOOLS 13b Connect fuel supply line quick connect fitting to 90 degree inlet adapter ensuring the line is not kinked binding or restricted 13c If clearance is not an issue connect fuel supply line quick connect fitting to straight inlet ensuring the line is not kinked binding or restricted 14 Connect the vehicle electrical connector to the pump electrical connector Make sure the connection is secure If the vehicle connector is damaged it must be replaced 15 Reconnect and tighten the negative battery cables at both batteries 16 Bleed any air from the supply line and the fuel pump by cycling the ignition key on off until all air is removed SEE VEHICLE REPAIR MANUAL FOR FURTHER INFORMATION 17 Start the engine check and correct any fuel leaks Remove the drain pan and test drive the vehicle For installation assistance call 1 800 424 7839 Cable Clamp Harness Capnut Cable Clamp Harness Fuel Line Quick Connector Mounting Nuts Washers Vehicle s Steel Fuel Line Banjo Mounting Nuts Washers Fuel Line Banjo Bolt 6 11 12 13b 7 8 10 9 Fuel Line Quick Connector 13c 6451 X91205 Instructions 5 8 08 9 30 AM Page 2
